Hardrock Tunnel Boring Machines
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1 Bernhard Maidl, Leonhard Schmid, Willy Ritz, Martin Herrenknecht Hardrock Tunnel Boring Machines In co-operation with Gerhard Wehrmeyer and Marcus Derbort -=rnst & Sohn '-A Wiley Company
2 Contents 1 Historical Development and Future Challenges 2 Basic Principles and Definitions Basic Principles and Construction Boring System Thrust and Clamping System Muck Removal System Support System Definitions and Terms Tunnel Boring Machines with Full-Face Excavation Gripper TBM Shielded TBM Tunnel Boring Machines for Partial Excavation 23 3 Boring Operation The Boring Process The Cutter Head Shape ofthe Cutter Head Clearing the Muck in the Excavation Area Cutter Head Construction and Soil Consolidation Cutting Tools General Working Method of Cutter Discs Cutter Spacing Penetration Wear Wear and Water Cutter Housing The Main Drive Types ofmain Drive Main Bearing Advance Rate Special Types Reamer TBMs Bouygues System Mobile Miner (Robbins) Back-Cutting Technology Mini-Fullfacer (Atlas Copco) Continuous Miner Shaft Sinking Raise Boring 62
3 VIII Contents 3652 Blind Drilling Combinations 65 4 Thrust General Advance with Gripper Clamping Advance with a Shield TBM 72 5 Material Transport Material Transport at the Machine Material Transport Through the Tunnel Rail Transport Diesel or Electric Operation Muck Cars Loading in the Tunnel Train Timetable Tunnel Track Trackless Operation Transport Vehicles Haul Road Loading Conveyor Transport Conveyor Storage Conveyor Belt Extension and Belt Operation Advantages of Conveyor Transport and Innovation Potential 87 6 Backup Equipment Backup Concept Design Specifications 93 7 Ventilation, Dust Removal, Working Safety,Vibration Ventilation Danger Ventilation Schemes, Ventilation Systems Dust Removal Occupational Safety and Safety P1anning for TBM Operation General International Guidelines and National Regulations International Guidelines National Regulations Integrated Safety Plan The Safety Plan in the Environment ofmanagement Plans Safety Aims Description ofdangers and Risk Analyses 107
4 Contents IX 7334 Action Plan TBM Details and Specifics Regarding Natural Gas Danger and Rock Support Natural Gas Danger Rock Support Vibration Additional Equipment Investigation and Improvement ofthe Geological Conditions Equipment for Rock Support Anchor Drills Steel Ring Equipment Mesh Installation Equipment Innovation Aims TBM Steering Steering the Gripper TBM with Single Bracing Steering the Gripper TBM with X-Type Clamping Steering a Single Shield TBM Steering a Double Shield TBM Surveying Surveying the Position ofthe Tunnel Boring Machine Forward Calculation ofthe TBM Route Tunnel Support General Support Systems and Advance Rates Systematic Support at the Machine Steel Arch Support Liner Plates Segments lnvert Segments Segmental Lining Shotcrete Support Shotcrete Support at the Machine Shotcrete Support in the Backup Area Localised Support Anchors and Mesh Arch Support Stabilisation Ahead ofthe Cutter Head Gripper TBM and Shield Machine Combinations Roof Shields Roof Shield and Side Steering Shoes and Cutter Head Shields Walking Blade Gripper TBM 153
5 x Contents Full-Face Shield Machines ISS Developments 155 Special Characteristics 156 Cutter Head and Shie1d 157 Thrust Ring 157 Double Shields 159 Developments 159 Functional Principle 159 Special Cases 160 Shield and Bentonite Lubrication 160 Telescopic Shield 161 Siurry Shield Machines 163 Developments 163 Working Principle 163 Shields with Screw Conveyors 165 Developments 165 Working Principle 165 Machine Types 167 Open Mode (Screw Conveyor - Conveyor Belt) 167 Closed Mode (Screw Conveyor - Conveyor Belt) 167 Closed Mode (Slurry Circuit) 168 EPB Mode (Screw Conveyor -- Conveyor Belt or Screw Conveyor/Slurry Pump) 169 Open Mode (Conveyor Belt) 170 Micro Machines for Hard Rock 172 Mini TBM 172 Pipe Jacking 174 Press-Boring Pipe Jacking 174 Shield Pipe Jacking 174 Special Processes : Combinations of TBM Drives with Shotcrete 177 Scope of App1ication 177 Construction Options 178 Probe Headings 178 Pilot Headings 180 Enlargement for Stations, Points or Machine Halls 181 Examples 183 Piora-Mulde Probe Heading 183 Kandertal Probe Heading 184 Uznaberg Pilot Heading 188 En1argement at the Connecting Structure at Nidelbad Zürich-Thalwil Tunnel 190
6 Geological Investigations and Intluences 195 General 195 Influences on the Boring Process 199 Influences on the Machine Clamping 202 Influences on the Rock Support 205 Classification for Excavation and Support 207 General and Objectives for Mechanised Tunnel1ing 207 Classification Systems 208 Classification According to Rock Properties 208 RMR System (Rock Mass Rating System) 208 Q System (Quality System) 211 C1assification According to Cuttability and Abrasiveness 220 Classification According to Type, Extent and Location ofthe Support Work Required 222 Standards, Guidelines and Recommendations für the C1assification of Mechanised Tunnel1ing 223 C1assification in Germany, 223 Classification in Austria 228 Classification in Switzerland 234 Classification Suggestion by the Authors 239 Tendering, Award, Contract 243 Procedure Examples 243 Procedure in Switzerland 243 General 243 Tender Evaluation 244 Quality Management 245 Assignment of Risks in the Contract 246 Geological1y or Geotechnically Altered Conditions, Altered Orders, Altered Schedules 249 Procedure in the Netherlands 249 Tendering and Negotiation Procedure with the Botlek Tunnel as an Example 249 Procedure in Germany 252 Design and Geotechnica1 Requirements in the Tendering of a Mechanised Tunnelling as Alternative Proposal 253 Introduction 253 Examples 253 Adler Tunnel 253 Sieberg Tunnel 254 Stuttgart Airport Tunnel 255 Rennsteig Tunnel 257 Lainz Tunnel 258 XI
7 XII Contents 1423 Additional Requirements for Mechanised Tunnelling Concept in the Tender Documents Geology and Hydrology Design and Construction Process Specification and Contract Decisions Based on Cost Design Phase and Preparation far Tendering Tendering Phase Construction Phase and Final Payment Forecast Tunnel Lining 265 General 265 Design Principles for Tunnel Linings 265 Single-Shell and Double-Shell Construction 265 Watertight and Water-Draining Forms ofconstruction 267 Lining with Concrete Segments 269 General 269 Construction Types 271 Block Segments with Right-Angled Plan 271 Hexagonal or Honeycomb Segments 274 Rhomboidal and Trapezoidal Segment Systems 275 Expanding Segments 276 Yielding Lining Systems 277 Joint Detailing 282 Longitudinal Joints 282 Ring Joints 286 Steel Fibre Concrete Segments 289 Grouting Annular Gap 290 Filling with Gravel 290 Mortar Grouting 291 Measures for Waterproofing Tunnels with Segment Linings 291 Sealing Bands 292 Injecting 294 Segment Production 295 Damages 296 Damage During Ring Erection 297 Damage During Excavation 297 Damage at the Shield Tail Seal 298 Damage after Leaving the Shield 298 Repair of Damage 299 Cast in-situ Linings 299 General 299 Construction 300
8 Contents XIII 1543 Manufacture Shotcrete Layers as the Final Lining 30 I 156 Structurallnvestigations Examples of Completed Tunnels Tunnel Excavation with Gripper TBMs Contro1 and Drainage Tunnel, Ennepe Reservoir Manapouri Underwater Tunnel, New Zea1and Tunnelling with Shie1d TBMs San Pellegrino Tunnel, ltaly Zürich-Thalwi1 Twin-Track Tunnel, Section Brunau-Thalwi lnclined Shaft Tunnelling with Double Shield Cleuson-Dixence Pressure Shaft 321 References 327 Index 337
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